Aircraft floor panels using edge coated honeycomb

Abstract

Aircraft floor panels where core-skin bonding is improved between honeycomb and composite face sheets (skins) by applying a nylon-based (polyamide) adhesive to the edge of the honeycomb prior to bonding. Edge coating of the honeycomb allows one to reduce panel weight without reducing the performance parameters that are required for different types of aircraft floor panels.

1. A method for making an aircraft floor panel comprising the steps of:
 providing an uncured first face sheet comprising an interior surface for bonding to said honeycomb and an exterior floor surface, said first face sheet comprising at least one fiber layer and an uncured thermosetting resin matrix; 
 providing a second face sheet comprising an interior surface for bonding to said honeycomb and an exterior surface, said second face sheet comprising an interior surface for bonding to said honeycomb; 
 providing a honeycomb having walls that define a plurality of honeycomb cells wherein said walls have a first edge for bonding to the interior surface of said first face sheet and a second edge for bonding to the interior surface of said second face sheet; 
 applying a polyamide adhesive solution to said first edge to form an edge-coated honeycomb wherein said polyamide adhesive solution comprises a polyamide dissolved in a solvent for said polyamide; and 
 bonding said uncured first face sheet and said second face sheet to said edge-coated honeycomb, said bonding comprises the step of curing said uncured thermosetting resin matrix. 
 
     
     
       2. A method for making an aircraft floor panel according to  claim 1  wherein said aircraft floor panel is an aisle floor panel. 
     
     
       3. A method for making an aircraft floor panel according to  claim 1  wherein said aircraft floor panel is an under seat floor panel. 
     
     
       4. A method for making an aircraft floor panel according to  claim 1  wherein said aircraft floor panel is a galley floor panel. 
     
     
       5. A method for making an aircraft floor panel according to  claim 1  wherein said aircraft floor panel is a high load floor panel. 
     
     
       6. An uncured aircraft floor panel comprising:
 a first face sheet comprising an interior surface for bonding to said honeycomb and an exterior floor surface, said first face sheet comprising at least one fiber layer and an uncured thermosetting resin matrix;
 a second face sheet comprising an interior surface for bonding to said honeycomb and an exterior surface, said second face sheet comprising an interior surface for bonding to said honeycomb; 
 
 a honeycomb having walls that define a plurality of honeycomb cells wherein said walls have a first edge for bonding to the interior surface of said first face sheet and a second edge for bonding to the interior surface of said second face sheet; and 
 a polyamide adhesive located between said first edge and the interior surface of said first face sheet wherein said polyamide adhesive is formed by applying a polyamide adhesive solution to said first edge wherein said polyamide adhesive solution comprises a polyamide and a solvent for said polyamide and wherein said solvent is evaporated to form said polyamide adhesive. 
 
     
     
       7. An aircraft floor panel according to  claim 6  wherein said uncured aircraft floor panel has been cured to provide a cured aircraft floor panel and wherein said cured aircraft floor panel is an aisle floor panel. 
     
     
       8. An aircraft floor panel according to  claim 6  wherein said uncured aircraft floor panel has been cured to provide a cured aircraft floor panel and wherein said cured aircraft floor panel is an under seat floor panel. 
     
     
       9. An aircraft floor panel according to  claim 6  wherein said uncured aircraft floor panel has been cured to provide a cured aircraft floor panel and wherein said cured aircraft floor panel is a galley floor panel. 
     
     
       10. An aircraft floor panel according to  claim 6  wherein said uncured aircraft floor panel has been cured to provide a cured aircraft floor panel and wherein said cured aircraft floor panel is a high load floor panel. 
     
     
       11. An aircraft comprising a fuselage that comprises an uncured floor panel in accordance with  claim 6  wherein said uncured floor panel has been cured to provide a cured floor panel. 
     
     
       12. An aircraft according to  claim 11  wherein said cured aircraft floor panel is an aisle floor panel. 
     
     
       13. An aircraft according to  claim 11  wherein said cured aircraft floor panel is an under seat floor panel. 
     
     
       14. An aircraft according to  claim 11  wherein said cured aircraft floor panel is a galley floor panel. 
     
     
       15. An aircraft according to  claim 11  wherein said cured aircraft floor panel is a high load floor panel. 
     
     
       16. A method for making an aircraft floor panel according to  claim 1  wherein said second face sheet is an uncured face sheet that comprises at least one fiber layer and an uncured thermosetting resin matrix and wherein a polyamide adhesive solution is also applied to said second edge to form an edge-coated honeycomb wherein both said first and second edges are coated with said polyamide adhesive solution and wherein said bonding comprises the step of curing said uncured thermosetting resin matrix in both said first and second uncured face sheets. 
     
     
       17. An uncured aircraft floor panel according to  claim 6  wherein said second face sheet is an uncured face sheet that comprises at least one fiber layer and an uncured thermosetting resin matrix and wherein a polyamide adhesive solution is also located only between said second edge and the interior surface of said uncured second face sheet. 
     
     
       18. An aircraft floor panel according to  claim 17  wherein said uncured thermosetting resin matrices have been cured.